ILD Series™ Maintenance & Service Manual

Design Detail

ILD Series Liftgate

Lift Cylinder

Column Column
Left Hand Right Hand

Slider Wear
Pads

Hydraulic
Open & Close
cylinder (“POC”)
Slider
Left Hand

Inner Section,
Platform

Outer Section,
Platform

Slider
Right
Hand
Hinge Tube,
Slider

Ramp
Hinge Pin
Platform

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ILD Series™ Maintenance & Service Manual

Design Detail

Power System

Lift Cylinder Flow Control Valve

Control Switch
Assembly
12 Volt
Power Supply

Power Unit

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ILD Series™ Maintenance & Service Manual

1. PREVENTIVE MAINTENANCE

1.1 Essential Maintenance

We strongly recommend that operators use our preventive maintenance

schedule as a means of keeping their liftgate running at its best. We
recommend that the Daily Overall Inspection should be performed by
the operator each day. As well, we recommend that the operator
perform the Periodic Lubrication according to the chart on page 11.
The Routine Maintenance Inspection should be performed semi-
annually by an Authorized Service Center. Performing Daily Overall
Inspection and Periodic Lubrication and having semi-annual Routine
Maintenance Inspections performed, should ensure years of safe,
trouble free operations.

The operator’s first visit to an Authorized Service Center should occur

once the liftgate has been in operation for 30 days. The importance of
this initial inspection is to make sure that everything is working properly
during this break in period. Once this is complete, we recommend that
the operator return semi-annually to his or her Authorized Service
Center for performance of the Routine Maintenance Inspection.

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ILD Series™ Maintenance & Service Manual

1.2 Daily Overall Inspection

STEP 1 Run liftgate through its entire

cycle daily. Check for any
unusual noises coming from
the liftgate or related items
such as the power unit.

STEP 2 Inspect liftgate for missing or

loosened fasteners, broken
welds, signs of overload,
hydraulic leaks and that pins
are in place and secured.
Any defects need repair
immediately. Contact your
Authorized Service Center.

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ILD Series™ Maintenance & Service Manual

1.2 Daily Overall Inspection

STEP 3 Check that all warning decals are in place and legible.
Any missing or damaged decals need replacement immediately.

1. Operating Instructions 4. Urgent Warning

2. Warning Keep Clear 5. Warning Liftgate Can Crush
3. Warning Maximum Load Capacity

You may obtain free replacement decals (See page 17 for detailed
description of decals) by phoning us at 888-774-5844 in USA.
Have your liftgate model # and serial # ready.

NOTE: Please fill out the chart provided, as a reminder that these
steps have been completed daily. You will find a sample of this chart on
the page that follows. Contact your employer to receive a copy to keep
in your glove compartment.

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ILD Series™ Maintenance & Service Manual

1.3 Periodic Lubrication

Lubrication with lightweight machine oil should be performed at least

monthly. Heavier usage will require more frequent lubrication consult
the chart below. If you are in any doubt as to duty or number of cycles,
lubricate more frequently.

Cycles per Day Light Duty1 Medium Duty2 Heavy Duty3

Under 20 1 month 1 month 1 month

20-40 1 month 1 month 2 weeks

40-60 1 month 2 weeks Weekly

Over 60 Consult factory Consult factory Consult factory

1
Lowering rated load and lifting empty platform
2
Lowering rated load and lifting 1/2 rated load
3
Lowering rated load and lifting

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ILD Series™ Maintenance & Service Manual

1.3 Periodic Lubrication

LUBRICATION DIAGRAM
Lubricate only the areas shown on the diagram below. Lubrication
of any other areas will shorten the life of the area lubricated.

Oil - Wear Pads

Upper Back and Upper Front
both sides

Oil - Wear Pads

Lower Back
Grease - Platform both sides
Hinge PIns both
sides

Grease - Platform
Folding Pin
both sides

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ILD Series™
2. TROUBLE SHOOTING
Problem Possible Cause
Liftgate will not raise or • Motor not running
raises slowly, unloaded
• Little or no hydraulic oil
in the reservoir
• No oil supply to cylinder
• Defective lift cylinder
• Hydraulic flow valve
on cylinders
malfunctioning
• Mechanical damage
or obstruction
• Hydraulic oil thickened
due to low temperature
15
Maintenance & Service Manual
Remedy
• Check Master Disconnect
is "ON"
• Check that Circuit Breaker
has not been tripped
• Check for shorts, ground
faults or open circuits,
e.g., power lines
connected to the ground
or a broken cable or
connection
• In below freezing
temperatures, check for
frozen water accumulation
in the motor housing
• Check motor solenoid.
Replace if non-functional
• Check control switch.
Replace if non-functional
• Fill with correct
hydraulic fluid
• Check for any broken or
blocked hoses, valves
or filters
• Check function. Replace if
non-functional
• Check function. Replace if
non-functional
• Check for and remedy
any damage or
obstruction in sliders,
track or path of travel
of platform
• Change to lower viscosity
hydraulic oil
ILD Series™
2. TROUBLE SHOOTING
Problem Possible Cause
Liftgate will not raise or • Reduced hydraulic oil
raises slowly, loaded delivery to the cylinder
• Ground Fault
• Liftgate overloaded
• Pump worn
• Pressure relief valve out
of adjustment
Liftgate will not raise to • Insufficient oil
full height in reservoir
• Air in hydraulic system
• Mechanical damage
or obstruction
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Maintenance & Service Manual
Remedy
• Check voltage supply
to motor. Minimum
should be 10.5 volts
under load. If voltage is
too low, increase the
power supply
• Check for poor electrical
connections
• Check the ground from
the chassis to the
battery (minimum #4
battery cable)
• Check the ground from
the chassis to the
motor (minimum #4
battery cable)
• Decrease load
• Have pump serviced
or replace
• Adjust
• Fill with hydraulic oil
• Raise and lower the
liftgate several times and
then fill the reservoir with
hydraulic oil
• Check for and remedy
any damage or
obstruction in sliders,
track or path of travel
of platform
ILD Series™
2. TROUBLE SHOOTING
Problem Possible Cause
Liftgate will not descend, or • Motor not running
does so slowly
• Little or no hydraulic oil
in the reservoir
• No oil supply to cylinder
• Defective lift cylinder
• Hydraulic locking valve
on power unit
malfunctioning
• Mechanical damage
or obstruction
• Hydraulic oil thickened
due to low temperature
17
Maintenance & Service Manual
Remedy
• Check Master Disconnect
is "ON"
• Check that Circuit Breaker
has not been tripped
• Check for shorts, ground
faults or open circuits,
e.g., power lines
connected to the ground
or a broken cable or
connection
• In below freezing
temperatures, check for
frozen water accumulation
in the motor housing
• Check motor solenoid.
Replace if non-functional
• Check control switch.
Replace if non-functional
• Fill with correct
hydraulic fluid
• Check for any broken or
blocked hoses, valves
or filters
• Check function. Replace if
non-functional
• Check function. Replace if
non-functional
• Check for and remedy
any damage or
obstruction in sliders,
track or path of travel
of platform
• Change to lower viscosity
hydraulic oil
ILD Series™
2. TROUBLE SHOOTING
Problem
Liftgate will not descend, or
does so slowly (cont.)
Liftgate creeps down while
the platform is in the
unfolded position
Maintenance & Service Manual
Possible Cause
• Hydrauilic locking
valve stuck
• Reduced hydraulic oil
delivery to the cylinder
• Ground Fault
• Leaks in the
hydraulic system
• Worn lift cylinder(s)
• Hydraulic locking valve
on power unit defective
• Electrical short circuit
18
Remedy
• Check for poor electrical
connections
• Check voltage supply to
motor. Minimum should
be 10.5 volts under load.
If voltage is too low,
increase the power supply
• Check the ground from
the chassis to the
battery (minimum #4
battery cable)
• Check solenoid for
proper operation
• Clean or replace
control valve
• Check all hoses,
connections and control
valves; replace or service
any faulty parts
• Check cylinder packing.
Replace if necessary
• Check cylinder for scoring.
Replace if necessary
• Clean or replace
• Check plunger assembly
for proper adjustment
• Check for short circuit at
valve pin
• Check for electrical
short circuit.
ILD Series™
2. TROUBLE SHOOTING
Problem
Liftgate descends unevenly
Liftgate vibrates up and
down while lifting
Excessive battery discharge
Maintenance & Service Manual
Possible Cause
• Defective flow control
valve on passenger side
cylinder
• Defective lift cylinder
• Mechanical damage
or obstruction
• Defective lift cylinder
• Air in system
• Tank breather is plugged
• Low pressure feed to
pump is restricted
• Alternator/generator not
working properly
• Frequent use with
insufficient charging time
• Defective battery
• Defective pump motor
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Remedy
• Replace
• Replace
• Check for and remedy any
damage or obstruction in
sliders, track or path of
travel of platform
• Check function. Replace
if non-functional
• Lower platform to ground
and fill reservoir. Now
raise and lower the
platform several times.
Refill reservoir if
necessary
• Unplug breather
• Remove restriction
• Service or replace
• Check battery water level
frequently
• Avoid use for frequent
short periods without
allowing adequate
recharging time. Do not
use liftgate with engine off
• Replace battery
• Replace motor
ILD Series™
2. TROUBLE SHOOTING
Problem Possible Cause
Overflowing through • Over filled reservoir
reservoir breather
• Air in system
Platform will not open or • Hydraulic system fault
close, or does so slowly
• Orfice in fitting on
open/close cylinder is
plugged
• Defective power unit
• Ground Fault
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Maintenance & Service Manual
Remedy
• Drain to proper volume
• Raise and lower the
platform several times,
refill if necessary
• Check hoses for kinks or
sharp bends and reroute
if necessary
• Check to make sure
orifice is not blocked at
POC cylinder end
• Check POC cylinder
seals. Replace if defective
• Check valves on power
unit for function
• Check electrical wiring
for sufficient current
(min. 10.5 volts) to valves
• Check electrical
connections
• Check the ground from
the chassis to the
battery (minimum #4
battery cable)
• Check the ground from
the chassis to the
motor (minimum #4
battery cable)